Search Results (194)

To enhance the electromagnetic performance of flat-wire permanent magnet synchronous motors, three different groove structures were designed for the rotor, and a multi-objective optimization algorithm combining a genetic algorithm (GA) with the TOPSIS method was proposed. Firstly, an 8-pole 48-slot flat-wire motor model was established, and the cogging torque was analytically calculated to compare the motor’s performance under different groove schemes. Secondly, global multi-objective optimization of the rotor groove dimensions was performed using a combined simulation approach involving Maxwell, Workbench, and Optislang, and the optimal rotor groove size structure was selected using the TOPSIS method. Finally, a comparative analysis of the motor’s performance under both rated-load and no-load conditions was conducted for the pre- and post-optimization designs, followed by verification of the mechanical strength of the optimized rotor structure. The research results demonstrate that the combined optimization approach utilizing the genetic algorithm and the TOPSIS method significantly enhances the torque characteristics of the motor. The computational results indicate that the average torque is increased to 165.32 N·m, with the torque ripple reduced from 28.37% to 13.32% and the cogging torque decreased from 896.88 mN·m to 187.9 mN·m. Moreover, the total distortion rates of the air-gap magnetic flux density and the no-load back EMF are significantly suppressed, confirming the rationality of the proposed motor design. Full article

Permanent magnetic couplings provide critical advantages for deep-sea systems through static-sealed, contactless power transmission. However, conventional metallic isolation sleeves incur significant eddy current losses, limiting efficiency and high-speed operation. Limited torque capacities fail to meet the operational demands of harsh marine environments. This study presents a novel permanent magnet coupling featuring a ceramic isolation sleeve engineered for deep-sea cryogenic ammonia submersible pumps. The ceramic sleeve eliminates eddy current losses and provides exceptional corrosion resistance in acidic/alkaline environments. To withstand 3.5 MPa hydrostatic pressure, a 6-mm-thick sleeve necessitates a 10 mm operational air gap, challenging magnetic circuit efficiency. To address this limitation, an improved 3D magnetic equivalent circuit (MEC) model was developed that explicitly accounts for flux leakage and axial end-effects, enabling the accurate characterization of large air gap fields. Leveraging this model, a Taguchi method-based optimization framework was implemented by balancing key parameters to maximize the torque density. This co-design strategy achieved a 21% increase in torque density, enabling higher torque transfer per unit volume. Experimental validation demonstrated a maximum torque of 920 Nm, with stable performance under simulated deep-sea conditions. This design establishes a new paradigm for high-power leak-free transmission in corrosive, high-pressure marine environments, advancing applications from deep-sea propulsion to offshore energy systems. Full article

The Halbach array permanent magnet can improve the power density of motors. This paper uses analytical modeling to analyze and optimize the Halbach array permanent magnet synchronous motor (PMSM). Firstly, a general motor model is established to obtain the air gap flux density. Secondly, the flux linkage and back electromotive force (EMF) were calculated. The analytical results are consistent with the finite element model (FEM) results. Thirdly, the effects of slot opening, magnetization angle, and main magnetic pole width on air gap flux density and back-EMF were studied. Finally, based on the optimization results, a prototype was manufactured, and performance testing was conducted successfully. Verification of the back-EMF of the prototype shows that the relative errors between FEM and the measured values are 1.1%, and the relative errors between the analytical values and measured values are 1.6%, which verifies the accuracy of the proposed analytical modeling. The proposed analytical model is universal and can be used to quickly adjust the magnetization form, magnetization angle, and pole width without remodeling in the finite element software, which is convenient for optimizing parameters in the early stage of motor design. Full article

In this study, we present the design and electromagnetic performance optimization of a micro-electromechanical system (MEMS) miniature outer-rotor permanent magnet motor. With increased attention towards higher torque density and lower torque pulsations in MEMS micromotor designs, an adaptation of an external rotor can be highly attractive. However, with the design complexity involved in such high-performance MEMS outer-rotor motor designs, the ultra-miniature 3D coil structures and the thin-film topology surrounding the air gap have been one of the main challenges. In this study, an ultra-thin outer-rotor motor with 3D MEMS silicon-based coils and a MEMS-compatible manufacturing method for the 3D coils is presented. Additionally, finite element simulations are conducted for the thin-film topology around the air gap to optimize performance characteristics such as torque developed, torque pulsations, and back electromotive force amplitude. Ultimately, the average magnetic flux density increased by 37.1%, from 0.361 T to 0.495 T. The root mean square (RMS) value of the back EMF per phase rises by 14.4%. Notably, the average torque is improved by 11.3%, while the torque ripple is significantly reduced from 1.281 mNm to 0.74 mNm, corresponding to a reduction of 49.9% in torque ripple percentage. Full article

Medium- and large-scale heat sinks are critical for thermal load management in high-performance systems. However, their high heat flux densities and limited space complicate cooling, leading to risks of overheating, performance degradation, or failure. This study employs the Cascaded Lattice Boltzmann Method (CLBM) to enhance their thermal performance. This numerical approach is known for being stable, accurate when dealing with complex boundaries, and efficient when computing in parallel. The numerical code was validated against a benchmark configuration and an experimental setup to ensure its reliability and accuracy. While previous studies have explored mixed convection in cavities or heat sinks, few have addressed configurations involving side air injection and boundary conditions periodicity in the transition-to-turbulent regime. This gap limits the understanding of realistic cooling strategies for compact systems. Focusing on mixed convection in the transition-to-turbulent regime, where buoyancy and forced convection interact, the study investigates the impact of Rayleigh number values ($5\times {10}^7$ to $5\times {10}^8$) and Reynolds number values (${10}^3$ to $3\times {10}^3$) on heat transfer. Simulations were conducted in a rectangular cavity with periodic boundary conditions on the vertical walls. Two heat sources are located on the bottom wall ($T_h$ = 50 °C). Two openings, one on each side of the two hot sources, force a jet of fresh air in from below. An opening at the level of the cavity ceiling’s axis of symmetry evacuates the hot air. Mixed convection drives the flow, exhibiting complex multicellular structures influenced by the control parameters. Calculating the average Nusselt number (Nu) across the surfaces of the heat sink reveals significant dependencies on the Reynolds number. The proposed correlation between Nu and Re, developed specifically for this configuration, fills the current gap and provides valuable insights for optimizing heat transfer efficiency in engineering applications. Full article

This study proposes a novel air gap structure to enhance the sensitivity and saturation resistance of high-frequency current transformers (HFCTs) used in partial discharge (PD) detection for high-voltage equipment. While previous research has shown that air gaps can prevent core saturation, the impact of asymmetrical versus symmetrical air gaps has not been systematically analyzed. In this paper, we perform a detailed simulation-based comparison using Material 43 and Material 78 ferrite cores. The results show that asymmetrical air gaps significantly increase flux density and improve sensitivity compared with symmetrical designs, achieving a flux enhancement of up to 40%. A physical mechanism based on flux concentration and reduced fringing effects is proposed to explain these improvements. This study provides a new design strategy for HFCTs, enhancing their performance under high-current conditions and improving the reliability of online PD monitoring systems. Future work will involve experimental validation to further confirm these findings. Full article

This study presents the design, optimization, and experimental validation of a large-air-gap voice coil motor (LAG-VCM) for high-precision magnetic levitation vibration isolation in vacuum environments. Key challenges arising from a large air gap, including pronounced leakage flux and a reduced flux density, were addressed by employing the equivalent magnetic charge method and the image method for the modeling of permanent magnets. Finite element analysis was applied to refine the motor geometry and obtain high thrust, low ripple, and strong linearity. To mitigate the severe thermal conditions of a vacuum, a heat pipe-based cooling strategy was introduced to efficiently dissipate heat from the coil windings. The experimental results demonstrate that the optimized LAG-VCM delivers a thrust of 277 N with low ripple while effectively maintaining coil temperatures below critical limits for prolonged operation. These findings confirm the suitability of the proposed LAG-VCM for vacuum applications with stringent requirements for both a large travel range and stable, high-force output. Full article

The interior permanent magnet synchronous motors (IPMSMs) are extensively applied in the field of new energy vehicles due to their high-power density and excellent performance control. However, the iron loss has a significant impact on their performance. This study conducts an optimization analysis on the processing technology of silicon steel sheets and motor structure, targeting the reduction of iron loss and the improvement of the motor’s integrated efficiency. Firstly, the influences of two iron core processing technologies on iron loss, namely gluing and welding, are compared. Through experimental tests, it is found that the iron loss density of the gluing process is lower than that of the welding process, and as the magnetic flux density increases, the difference between the two is expanding. Therefore, the iron loss test data from the adhesive process are employed to develop a variable-coefficient iron loss model, enabling precise calculation of the motor’s iron loss. On this basis, aiming at the problem of excessive iron loss of the motor, a novel topological structure of the stator and rotor is proposed. With the optimization goal of reducing the motor iron loss and taking the connection port of the air magnetic isolation slot and the gap of the stator module as the optimization variables, the optimized design of the IPMSM with low iron loss is achieved based on the Taguchi method. After optimization, the stator iron loss decreases by 13.60%, the rotor iron loss decreases by 20.14%, and the total iron loss is reduced by 15.34%. The optimization scheme takes into account both the electromagnetic performance and the process feasibility, it offers technical backing for the high-efficiency operation of new energy vehicle drive motors. Full article

In this paper, the concept of symmetry is utilized to optimize the structural parameters and output characteristics of the generator design—that is, the construction and solution of the equivalent magnetic circuit method for the hybrid excitation generator are symmetrical. To address the issues of high excitation loss and low power density in purely electrically excited generators, as well as the difficulty in adjusting the magnetic field in purely permanent magnet generators, a new topology for a built-in permanent magnet and salient-pole electromagnetic hybrid excitation generator is proposed. Firstly, an equivalent magnetic circuit model of the generator is established. Secondly, expressions are derived to describe the relationships between the dimensions of the salient-pole rotor and the permanent magnets and the generator’s no-load induced electromotive force, cogging torque, and air gap flux density. These expressions are then used to analyze the structural parameters that influence the generator’s performance. Thirdly, optimization targets are selected through sensitivity analysis, with the no-load induced electromotive force, cogging torque, and air gap flux density serving as the optimization objectives. A multi-objective genetic algorithm is employed to optimize these parameters and determine the optimal structural matching parameters for the generator. As a result, the optimized no-load induced electromotive force increased from 18.96 V to 20.14 V, representing a 6.22% improvement; the cogging torque decreased from 177.08 mN·m to 90.52 mN·m, a 48.88% reduction; the air gap flux density increased from 0.789 T to 0.829 T, a 5.07% improvement; and the air gap flux density waveform distortion rate decreased from 6.22% to 2.38%, a 39.3% reduction. Finally, a prototype is fabricated and experimentally tested, validating the accuracy of the simulation analysis, the feasibility of the optimization method, and the rationality of the generator design. Therefore, the proposed topology and optimization method can effectively enhance the output performance of the generator, providing a valuable theoretical reference for the design of hybrid excitation generators for vehicles. Full article

Hybrid excited machines are strong competitors for application in hybrid/full electric vehicles due to their high torque density and strong air gap field-regulating capability. Similar to armature back-EMF, back-EMF also exists in the field windings of hybrid excited machines. However, the existence of field back-EMF is harmful to the safe and stable operation of machine systems, e.g., lower efficiency, higher torque ripple, reduced control performance, etc. In this paper, the influence of the hybridization ratio k, i.e., the ratio of the field winding slot area to the total field slot area, on the field back-EMF in hybrid excited machines with a switched flux stator is comprehensively investigated. In addition, a comparative study of the field back-EMF ripple in hybrid excited machines and wound field synchronous machines is conducted. It shows that the field back-EMF in flux-enhancing, zero field current, and flux-weakening modes is significantly affected by the hybridization ratio under different conditions. Moreover, the on-load field back-EMF in wound field machines is considerably higher than that in hybrid excited machines due to the mitigated magnetic saturation level in the field winding’s magnetic flux path. Finally, to validate the results predicted using the finite element method, a prototype hybrid excited machine is built and tested. Full article

This research examines the magnet structure’s effect on the performance of permanent magnet generators. The permanent magnet generator’s cogging torque (CT) is one of the characteristics that this article examines. In an electrical machine or permanent magnet generator, CT is a characteristic that can cause unwanted phenomena like vibration and noise. The permanent magnet generator’s magnetic flux density in the core is another crucial factor affecting the machine’s efficiency. The present study introduces this parameter. This study used the finite element method for magnetics to investigate and compare the values of the tangential and normal magnetic flux densities in air gaps. Using the magnet edge slotting technique might decrease the magnetic flux density, the total magnetic flux pouring into the air gap of the permanent magnet generator, and the CT reduction. It is demonstrated that using the two processes of slotting at the magnet edge can result in improved permanent magnet generator performance. The numerical calculation software FEMM 4.2, based on the finite element method, it was used to validate the CT of the permanent magnet generators under examination. It was discovered that the cogging torque of the proposed permanent magnet generator can be significantly increased—by about 99.3%—compared to the original design of the permanent magnet generators being studied. To retrieve the power that was lost when the magnet was cut, the authors improved the convex shape next to the rotor core. This made the magnet volume bigger, similar to the magnet design in the baseline model. The cogging torque was evaluated using FEMM and contrasted with the cogging torque of the baseline model. It was determined that the cogging torque diminished by 99.2% relative to that of the baseline model. This result is marginally lower than the reduction in the cogging torque value observed without employing convex magnets, which stands at 99.3%. Full article

In slotless machines, the winding conductors are exposed to the magnetic air gap field, which causes additional eddy current losses, thus decreasing efficiency and affecting thermal utilization. This is the case, inter alia, for axial flux motors equipped with printed circuit board windings, where the winding is made of copper–fiberglass epoxy laminations and located in the air gap. The dominant influencing factors are primarily the width of the conducting tracks and the magnetic air gap flux density and frequency. The evaluation time is a crucial constraint when calculating thousands of different designs for design space exploration or performing multi-objective optimizations. Finite element simulations can achieve very precise results, but unlike semi-analytical approximation functions, they are very time-consuming and therefore not the method of choice for design space exploration. This publication provides a comprehensive overview of a selection of different eddy current loss calculation techniques that are applicable for rectangular tracks and round wire windings. A comparison of the calculated results for a finite element simulation is presented for a slotless axial flux machine with printed circuit board windings and rectangular tracks. The calculation time consumed is also compared. The current density distribution of planar conductors of air gap windings differs from that in electrical steel sheets. In contrast to the methods based on steel sheets, only the adapted methods for conductors in air gaps offer acceptable accuracy. A recommendation is provided for the method that offers the best balance between accuracy and computation time for the early-stage design of slotless axial flux machines. Full article

Nowadays, motor type plays a significant role in the vehicle performances. This article compares various types of permanent magnet vernier motors (PMVMs) with different shapes of field modulation teeth and different numbers of field modulation poles (FMPs). Based on this, the electromagnetic performance of permanent magnet synchronous motors (PMSMs) and PMVMs is compared. First, the back EMF, air gap flux density, flux density distribution, and torque of PMVMs with different shapes of FMPs are compared. Based on the selected PMVMs, the rated torque and overload capacity of PMVMs with different slot–pole combinations are compared. Subsequently, the comprehensive electromagnetic performance of PMVMs and PMSMs is compared, where the strength and weakness of PMSMs and PMVMs are concluded. Finally, a prototype is manufactured and tested, verifying the correctness and accuracy of the simulation model. Full article

Owing to the distinct advantages of stator–permanent magnet (PM) motors over other PM machines, their prominence in high-power-density applications is surging dramatically, capturing growing interest across diverse applications. This article proposes an innovative design procedure for two primary stator–PM motor types, flux switching and biased flux, yielding 30 novel motor designs. The procedure involves splitting teeth, incorporating a flux reversal effect, and embedding flux barriers into the conventional structure. The analytical reasons behind the novel motors’ architecture are mathematically expressed and verified using finite element analysis (FEA). Through an effective optimisation based on a multi-objective genetic algorithm, various feasible stator/rotor pole combinations are explored, with over 36,000 samples evaluated using FEA coupled with the algorithm. The electromagnetic characteristics of promising motors are analysed, revealing that adding the flux reversal effect and flux barriers, which reduce PM volume while decreasing leakage flux and enhancing air gap flux, improves torque production by up to 68%. Beyond torque enhancement, other electromagnetic parameters, including torque ripple, core loss, and the power factor, are also improved. The proposed motors enhance the PM torque density significantly by about 115% compared to conventional motors and reduce the motor costs. A generalised decision-making process and thermal analysis are applied to the top-performing motors. Additionally, the prototyping measures and considerations are thoroughly discussed. Finally, a comprehensive conclusion is reached. Full article

The focus of this paper is to seek means of increasing induction motor efficiency to a comparable level to a permanent magnet motor. Harmonic and high-frequency losses increase the rotor core and copper loss, often limiting IM efficiency. The research in this study focuses on reducing rotor core and copper losses for this purpose. An accurate finite element model of a prototype motor is developed. The accuracy of this model in predicting the performance and losses of the prototype motor is verified with experiments over a 32 Hz–125 Hz supply frequency range. The verified model of the motor is used to identify the causes of the rotor core and copper losses of the motor. It is found that the air gap flux density of the motor contains many harmonics, and the slot harmonics are dominant. The distribution of the core loss and the copper loss is investigated on the rotor side. It is discovered that up to 35% of the rotor copper losses and 90% rotor core losses occur in the regions up to 4 mm from the airgap where the harmonics penetrate. To reduce these losses, one solution is to reduce the magnitude of the air gap flux density harmonics. For this purpose, placing a sleeve to cover the slot openings is investigated. The FEA indicates that this measure reduces the harmonic magnitudes and reduces the core and bar losses. However, its effect on efficiency is observed to be limited. This is attributed to the penetration depth of flux density harmonics inside the rotor conductors. To remedy this problem, several FEA-based modifications to the rotor slot shape are investigated to place rotor bars deeper than the harmonic penetration. It is found that placing the bars further away from the rotor surface is very effective. Using a 1 mm sleeve across the stator’s open slots combined with a rotor tapered slot lip positions the bars slightly deeper than the major harmonic penetration depth, making it the optimal solution. This reduces the bar loss by 70% and increases the motor efficiency by 1%. Similar loss reduction is observed over the tested supply frequency range. Full article